Apparatus and method for mechanically bonding and cutting an article

ABSTRACT

In a method and apparatus for mechanically bonding and cutting an article during assembly thereof at least a portion of the article is transported through a nip defined by first and second members. A bonding segment is disposed on one of the first and second members and a cutting segment separate from the bonding segment is also disposed on one of the first and second members. The apparatus is operable so that a portion of the article is mechanically bonded as the article passes through the nip and a portion of the article separate from the bonded portion is cut as the article passes through the nip.

BACKGROUND OF THE INVENTION

[0001] This invention relates generally to articles such as trainingpants, diapers, feminine hygiene products, incontinence garments,material webs and the like, and more particularly to apparatus andmethods for mechanically bonding and cutting such articles duringassembly thereof.

[0002] Articles such as absorbent articles find widespread use aspersonal care products including, without limitation, diapers,children's toilet training pants, adult incontinence garments, sanitarynapkins and the like, as well as surgical bandages and sponges. Thesearticles absorb and contain body waste and are usually intended to bediscarded after a limited period of use, i.e., the articles are notintended to be laundered or otherwise restored for reuse. Conventionalabsorbent articles comprise an absorbent body disposed between a liner,which contacts the wearer's skin, and an outer cover, which inhibitsliquid body waste absorbed by the absorbent body from leaking out of thearticle. The liner of the absorbent article is typically liquidpermeable to permit liquid body waste to pass therethrough forabsorption by the absorbent body.

[0003] Conventional absorbent articles also typically include some typeof fastening system for securing the absorbent article in an assembledconfiguration and/or for fitting the article on the wearer, such as onthe wearer's waist in the case of diapers and training pants. In manysuch applications, the fastening system is releasable and refastenableso that the article can be temporarily removed and then refastened tothe wearer.

[0004] One common form of fastening system is the so-calledhook-and-loop fastening system, which comes in various forms and hasboth advantages and disadvantages in its application to such absorbentarticles. For example, particularly when used for training pants,engageable hook and loop fasteners are secured respectively to the frontand back waist regions of the article generally at overlapping sidepanels of the article so that the fasteners releasably engage each otherto form the three dimensional shape of the article. In typical sucharticles, the loop fastener may form a portion of the article itself orbe attached to the side panel or other component of the article. Thehook fastener is generally attached to an extensible substrate (e.g.,the side panel) so that it can be suitably positioned in engagement withthe loop fastener material while allowing for various shapes and sizesof the intended wearers of the article.

[0005] Conventional apparatus for making absorbent articles such aschildren's training pants or diapers assemble the various components,such as the liner, outer cover, absorbent body, side panels (e.g., intraining pants) and fastening system (e.g. a hook and loop fasteningsystem). It is known to ultrasonically bond the fastening system to asubstrate such as the liner, outer cover and/or side panels. For examplea rotary ultrasonic bonding device comprising a rotary anvil roll andcorresponding horn roll may be used. The anvil roll has a plurality ofpins protruding therefrom about its circumference to thermally bond thefastening system to the substrate at discrete bond points.

[0006] The partially assembled article is often subsequently trimmedduring manufacture, e.g., by cutting out a portion of the outer edge ofthe liner, outer cover and/or side panels, to provide desiredform-fitting features of the article, such as the leg openings ofdiapers and training pants. A die cutting assembly, separate from theanvil roll and horn, is typically positioned downstream of the anvilroll for cutting the article, such as to form a tapered leg end edge ofthe side panels.

SUMMARY OF THE INVENTION

[0007] In one embodiment a method of the present invention formechanically bonding and cutting an article during assembly thereofgenerally comprises transporting the article in a machine directionduring assembly thereof such that at least part of the article passesthrough a nip as the article is transported in the machine direction. Aportion of the article is mechanically bonded as the article passesthrough the nip. A portion of the article separate from the bondedportion is cut as the article passes through the nip.

[0008] Apparatus of one embodiment of the present invention formechanically bonding and cutting an article upon movement of the articlein a machine direction generally comprises a first member and a secondmember arranged relative to the first member to define a niptherebetween for receiving the article therethrough upon movement of thearticle in the machine direction. A bonding segment is disposed on oneof the first and second members and is configured for mechanicallybonding the article. A cutting segment is also disposed on one of thefirst and second members and is configured for cutting the article. Theapparatus is operable in a bonding mode in which the nip is defined inpart by the bonding segment and the cutting segment is disposed externalof the nip such that a portion of the article is mechanically bonded asthe article passes through the nip. The apparatus is also operable in acutting mode in which the nip is defined in part by the cutting segmentand the bonding segment is disposed external of the nip whereby aportion of the article other than the bonded portion thereof is cut asthe article passes through the nip.

[0009] In another embodiment, the apparatus generally comprises a firstmember and a second member arranged relative to the first member todefine a nip therebetween for receiving the article therethrough uponmovement of the article in the machine direction. A bonding segment isdisposed on one of the first and second members and is configured formechanically bonding the article. A cutting segment is disposed on oneof the first and second members separate from the bonding segment and isconfigured for cutting the article. The apparatus is operable toposition the first and second members relative to each other at the nipsuch that at least one of the bonding segment and the cutting segment atleast partially defines the nip as the article passes therethrough.

DEFINITIONS

[0010] Within the context of this specification, each term or phrasebelow will include the following meaning or meanings.

[0011] “Bonded” refers to the joining, adhering, connecting, attaching,or the like, of two elements. Two elements will be considered to bebonded together when they are bonded directly to one another orindirectly to one another, such as when each is directly bonded tointermediate elements.

[0012] “Elastic,” “elasticized” and “elasticity” mean that property of amaterial or composite by virtue of which it tends to recover itsoriginal size and shape after removal of a force causing a deformation.

[0013] “Elastomeric” refers to a material or composite which can beelongated by at least 25 percent of its relaxed length and which willrecover, upon release of the applied force, at least 10 percent of itselongation. It is generally preferred that the elastomeric material orcomposite be capable of being elongated by at least 100 percent, morepreferably by at least 300 percent, of its relaxed length and recover,upon release of an applied force, at least 50 percent of its elongation.

[0014] “Extensible” refers to a material or composite that isstretchable or capable of being elongated in at least one direction, butwhich may not have sufficient recovery to be considered elastic.

[0015] “Flexible” refers to materials which are compliant and which willreadily conform to the general shape and contours of the wearer's body.

[0016] “Force” includes a physical influence exerted by one body onanother which produces acceleration of bodies that are free to move anddeformation of bodies that are not free to move. Force is expressed ingrams per unit area.

[0017] “Hydrophilic” describes fibers or the surfaces of fibers whichare wetted by the aqueous liquids in contact with the fibers. The degreeof wetting of the materials can, in turn, be described in terms of thecontact angles and the surface tensions of the liquids and materialsinvolved. Equipment and techniques suitable for measuring thewettability of particular fiber materials or blends of fiber materialscan be provided by a Cahn SFA-222 Surface Force Analyzer System, or asubstantially equivalent system. When measured with this system, fibershaving contact angles less than 90 degrees are designated “wettable” orhydrophilic, while fibers having contact angles greater than 90 degreesare designated “nonwettable” or hydrophobic.

[0018] “Integral” is used to refer to various portions of a singleunitary element rather than separate structures bonded to or placed withor placed near one another.

[0019] “Inward” and “outward” refer to positions relative to the centerof an article, and particularly transversely and/or longitudinallycloser to or away from the longitudinal and transverse center of thearticle.

[0020] “Layer” when used in the singular can have the dual meaning of asingle element or a plurality of elements.

[0021] “Longitudinal” and “transverse” have their customary meaning, asindicated by the longitudinal and transverse axes depicted in FIGS. 2and 3. The longitudinal axis lies in the plane of the article and isgenerally parallel to a vertical plane that bisects a standing wearerinto left and right body halves when the article is worn. The transverseaxis lies in the plane of the article generally perpendicular to thelongitudinal axis. The article as illustrated is longer in thelongitudinal direction than in the transverse direction.

[0022] “Nonwoven” and “nonwoven web” refer to materials and webs ofmaterial which are formed without the aid of a textile weaving orknitting process.

[0023] “Operatively joined,” with reference to the attachment of anelastic member to another element, means that the elastic member whenattached to or connected to the element, or treated with heat orchemicals, by stretching, or the like, gives the element elasticproperties; and with reference to the attachment of a non-elastic memberto another element, means that the member and element can be attached inany suitable manner that permits or allows them to perform the intendedor described function of the joinder. The joining, attaching, connectingor the like can be either direct, such as by joining the member directlyto an element, or can be indirect, such as by means of another memberdisposed between the member and the element.

[0024] “Permanently bonded” refers to the joining, adhering, connecting,attaching, or the like, of two elements of an article such that theelements tend to be and remain bonded during normal use conditions ofthe article.

[0025] “Refastenable” refers to the property of two elements beingcapable of releasable attachment, separation, and subsequent releasablereattachment without substantial permanent deformation or rupture.

[0026] “Releasably attached,” “releasably engaged” and variationsthereof refer to two elements being connected or connectable such thatthe elements tend to remain connected absent a separation force appliedto one or both of the elements, and the elements being capable ofseparation without substantial permanent deformation or rupture. Therequired separation force is typically beyond that encountered whilewearing the article.

[0027] “Stretch bonded” refers to an elastic member being bonded toanother member while the elastic member is extended at least about 25percent of its relaxed length. Desirably, the term “stretch bonded”refers to the situation wherein the elastic member is extended at leastabout 100 percent, and more desirably at least about 300 percent, of itsrelaxed length when it is bonded to the other member.

[0028] “Stretch bonded laminate” refers to a composite material havingat least two layers in which one layer is a gatherable layer and theother layer is an elastic layer. The layers are joined together when theelastic layer is in an extended condition so that upon relaxing thelayers, the gatherable layer is gathered.

[0029] These terms may be defined with additional language in theremaining portions of the specification.

BRIEF DESCRIPTION OF THE DRAWINGS

[0030]FIG. 1 is a side view of a pair of training pants with amechanical fastening system of the pants shown fastened on one side ofthe training pants and unfastened on the other side of the trainingpants;

[0031]FIG. 2 is a plan view of the training pants of FIG. 1 in anunfastened, stretched and laid flat condition, and showing the surfaceof the training pants that faces away from the wearer;

[0032]FIG. 3 is a plan view similar to FIG. 2, but showing the surfaceof the training pants that faces the wearer when worn, and with portionscut away to show underlying features;

[0033]FIG. 4 is a schematic view of one embodiment of apparatus formaking training pants according to the present invention;

[0034]FIG. 5 is a portion of a product assemblage at one point in theprocess illustrated in FIG. 4;

[0035]FIG. 6 is a schematic side elevation view of one embodiment ofmechanical bonding and cutting apparatus of the present invention;

[0036]FIG. 7 is a flat view of a circumferential outer surface of ananvil roll of the mechanical bonding and cutting apparatus of FIG. 6;

[0037]FIG. 8 is a fragmented cross-section taken in the plane of line8-8 of FIG. 7;

[0038]FIG. 9 is a fragmented cross-section taken in the plane of line9-9 of FIG. 7;

[0039]FIG. 10 is a flat view of an alternative embodiment of acircumferential outer surface of the anvil roll; and

[0040]FIG. 11 is a flat view of another alternative embodiment of acircumferential outer surface of the anvil roll.

[0041] Corresponding reference characters indicate corresponding partsthroughout the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0042] Referring now to the drawings and in particular to FIG. 1, anarticle in the form of children's toilet training pants is indicated inits entirety by the reference numeral 20 and incorporates a mechanicalfastening system, generally indicated at 80, of the present inventionfor securing the pants in an assembled, three dimensional form. Thearticle may or may not be absorbent, which generally refers to absorbentarticles that may be placed against or in proximity to the body of thewearer to absorb and/or retain various liquid waste discharged from thebody. The article may or may not also be disposable, which refers toarticles that are intended to be discarded after a limited period of useinstead of being laundered or otherwise restored for reuse. While theapparatus and methods of the present invention are shown and describedherein in connection with children's toilet training pants, it isunderstood that the apparatus and methods may be used to make variousother articles such as diapers, feminine hygiene products, incontinenceproducts, medical articles such as medical garments, surgical pads andbandages, other personal care or health care garments, swim pants,athletic clothing, pants and shorts, and the like without departing fromthe scope of the present invention. As used herein, the term article iscontemplated to also include discrete or continuous webs of materialincluding, but not limited to, wipes, towels, napkins and other materialwebs.

[0043] By way of illustration only, various materials and methods forconstructing the training pants 20 are disclosed in PCT PatentApplication WO 00/37009 published Jun. 29, 2000 by A. Fletcher et al;U.S. Pat. No. 4,940,464 issued Jul. 10, 1990 to Van Gompel et al.; andU.S. Pat. No. 5,766,389 issued Jun. 16, 1998 to Brandon et al., whichare incorporated herein by reference.

[0044] The pair of training pants 20 is illustrated in FIG. 1 in apartially fastened condition and comprises a front waist region 22, aback waist region 24, a crotch region 26 interconnecting the front andback waist regions, an inner surface 28 configured for contiguousrelationship with the wearer, and an outer surface 30 opposite the innersurface. With additional reference to FIGS. 2 and 3, the training pants20 also has a pair of laterally opposite side edges 36 and a pair oflongitudinally opposite waist edges, respectively designated front waistedge 38 and back waist edge 39. The front waist region 22 is contiguouswith the front waist edge 38, and the back waist region 24 is contiguouswith the back waist edge 39.

[0045] The illustrated pants 20 comprises a central absorbent assembly,generally indicated at 32, which when laid flat can be rectangular orany other desired shape, a pair of laterally opposite front side panels34 extending outward therefrom at the front waist region and a pair oflaterally opposite back side panels 134 extending outward therefrom atthe back waist region. The absorbent assembly 32 and side panels 34, 134may comprise two or more separate elements, as shown in FIG. 1, or beintegrally formed. The central absorbent assembly 32 of the illustratedembodiment comprises an outer cover 40, a bodyside liner 42 (FIGS. 1 and3) connected to the outer cover in a superposed relation, an absorbentbody 44 (FIG. 3) disposed between the outer cover and the bodysideliner, and a pair of containment flaps 46 (FIG. 3). The centralabsorbent assembly also has opposite ends 45 which form portions of thefront and back waist edges 38 and 39, and opposite side edges 47 whichform portions of the side edges 36 of the training pants 20 (FIGS. 2 and3). Integrally formed side panels 34, 134 and absorbent assembly 32would comprise at least some common materials, such as the bodysideliner, flap composite, outer cover, other materials and/or combinationsthereof, and could define a one-piece elastic, stretchable, ornonstretchable pants. For further reference, arrows 48 and 49 depict theorientation of the longitudinal axis and the transverse or lateral axis,respectively, of the training pants 20.

[0046] With the training pants 20 in the fastened position as partiallyillustrated in FIG. 1, the front and back side panels 34, 134 areconnected together by a fastening system 80 to define athree-dimensional pants configuration having a waist opening 50 and apair of leg openings 52. The front waist region 22 comprises the portionof the training pants 20 which, when worn, is positioned on the front ofthe wearer while the back waist region 24 comprises the portion of thetraining pants which is positioned on the back of the wearer. The crotchregion 26 of the training pants 20 comprises the portion of the trainingpants 20 which is positioned between the legs of the wearer and coversthe lower torso of the wearer. The front and back side panels 34 and 134comprise the portions of the training pants 20 which, when worn, arepositioned on the hips of the wearer. The waist edges 38 and 39 of thetraining pants 20 are configured to encircle the waist of the wearer andtogether define the waist opening 50 (FIG. 1). Portions of the sideedges 36 in the crotch region 26 generally define the leg openings 52.

[0047] The central absorbent assembly 32 is configured to contain and/orabsorb exudates discharged from the wearer. For example, the containmentflaps 46 are configured to provide a barrier to the transverse flow ofbody exudates. A flap elastic member 53 (FIG. 3) can be operativelyjoined with each containment flap 46 in any suitable manner as is wellknown in the art. The elasticized containment flaps 46 define apartially unattached edge which assumes an upright configuration in atleast the crotch region 26 of the training pants 20 to form a sealagainst the wearer's body. The containment flaps 46 can be located alongthe side edges 36 of the pants 20, and can extend longitudinally alongthe entire length of the absorbent assembly 32 or may only extendpartially along the length of the absorbent assembly. Suitableconstructions and arrangements for the containment flaps 46 aregenerally well known to those skilled in the art and are described inU.S. Pat. No. 4,704,116 issued Nov. 3, 1987 to Enloe, which isincorporated herein by reference.

[0048] To further enhance containment and/or absorption of bodyexudates, the training pants 20 also suitably includes a front waistelastic member 54 (FIG. 3), a rear waist elastic member 56, and legelastic members 58, as are known to those skilled in the art. The waistelastic members 54 and 56 can be operatively joined to the outer cover40 and/or the bodyside liner 42 along the opposite waist edges 38 and39, and can extend over part or all of the waist edges. The leg elasticmembers 58 can be operatively joined to the outer cover 40 and/or thebodyside liner 42 along the opposite side edges 36 and positioned in thecrotch region 26 of the training pants 20. The leg elastic members 58can be longitudinally aligned along each side edge 47 of the absorbentassembly 32. Each leg elastic member 58 has a front terminal point 63and a back terminal point 65, which represent the longitudinal ends ofthe elastic gathering caused by the leg elastic members.

[0049] The flap elastic members 53, the waist elastic members 54 and 56,and the leg elastic members 58 can be formed of any suitable elasticmaterial. As is well known to those skilled in the art, suitable elasticmaterials include sheets, strands or ribbons of natural rubber,synthetic rubber, or thermoplastic elastomeric polymers. The elasticmaterials can be stretched and adhered to a substrate, adhered to agathered substrate, or adhered to a substrate and then elasticized orshrunk, for example with the application of heat, such that elasticretractive forces are imparted to the substrate. In one particularembodiment, for example, the leg elastic members 58 comprise a pluralityof dry-spun coalesced multifilament spandex elastomeric threads soldunder the trade name LYCRA® and available from E. I. Du Pont de Nemoursand Company, Wilmington, Del. U.S.A.

[0050] The outer cover 40 desirably comprises a material which issubstantially liquid impermeable, and can be elastic, stretchable ornonstretchable. The outer cover 40 can be a single layer of liquidimpermeable material, but desirably comprises a multi-layered laminatestructure in which at least one of the layers is liquid impermeable. Forinstance, the outer cover 40 can include a liquid permeable outer layerand a liquid impermeable inner layer that are suitably joined togetherby a laminate adhesive, ultrasonic bonds, thermal bonds, or the like.Suitable laminate adhesives, which can be applied continuously orintermittently as beads, a spray, parallel swirls, or the like, can beobtained from Findley Adhesives, Inc., of Wauwatosa, Wis., U.S.A., orfrom National Starch and Chemical Company, Bridgewater, N.J. U.S.A. Theliquid permeable outer layer can be any suitable material and isdesirably one that provides a generally cloth-like texture. One exampleof such a material is a 20 gsm (grams per square meter) spunbondpolypropylene nonwoven web. The outer layer may also be made of thosematerials of which the liquid permeable bodyside liner 42 is made. Whileit is not a necessity for the outer layer to be liquid permeable, it isdesired that it provides a relatively cloth-like texture to the wearer.

[0051] The inner layer of the outer cover 40 can be both liquid andvapor impermeable, or it may be liquid impermeable and vapor permeable.The inner layer can be manufactured from a thin plastic film, althoughother flexible liquid impermeable materials may also be used. The innerlayer, or the liquid impermeable outer cover 40 when a single layer,prevents waste material from wetting articles, such as bed sheets andclothing, as well as the wearer and caregiver. A suitable liquidimpermeable film for use as a liquid impermeable inner layer, or asingle layer liquid impermeable outer cover 40, is a 0.02 millimeterpolyethylene film commercially available from Pliant Corporation ofSchaumburg, Ill., U.S.A.

[0052] If the outer cover 40 is a single layer of material, it can beembossed and/or matte finished to provide a more cloth-like appearance.As earlier mentioned, the liquid impermeable material can permit vaporsto escape from the interior of the disposable absorbent article, whilestill preventing liquids from passing through the outer cover 40. Asuitable “breathable” material is composed of a microporous polymer filmor a nonwoven fabric that has been coated or otherwise treated to imparta desired level of liquid impermeability. A suitable microporous film isa PMP-1 film material commercially available from Mitsui ToatsuChemicals, Inc., Tokyo, Japan, or an XKO-8044 polyolefin filmcommercially available from 3M Company, Minneapolis, Minn. U.S.A. Theouter cover 40 may also include appearance related components (notshown) as are well known in the art.

[0053] The liquid permeable bodyside liner 42 is illustrated asoverlying the outer cover 40 and absorbent body 44, and may but need nothave the same dimensions as the outer cover 40. The bodyside liner 42 isdesirably compliant, soft feeling, and non-irritating to the child'sskin. Further, the bodyside liner 42 can be less hydrophilic than theabsorbent body 44, to present a relatively dry surface to the wearer andpermit liquid to readily penetrate through its thickness. Alternatively,the bodyside liner 42 can be more hydrophilic or can have essentiallythe same affinity for moisture as the absorbent body 44 to present arelatively wet surface to the wearer to increase the sensation of beingwet. This wet sensation can be useful as a training aid. Thehydrophilic/hydrophobic properties can be varied across the length,width and depth of the bodyside liner 42 and absorbent body 44 toachieve the desired wetness sensation or leakage performance.

[0054] The bodyside liner 42 can be manufactured from a wide selectionof web materials, such as synthetic fibers (for example, polyester orpolypropylene fibers), natural fibers (for example, wood or cottonfibers), a combination of natural and synthetic fibers, porous foams,reticulated foams, apertured plastic films, or the like. Various wovenand nonwoven fabrics can be used for the bodyside liner 42. For example,the bodyside liner can be composed of a meltblown or spunbonded web ofpolyolefin fibers. The bodyside liner can also be a bonded-carded webcomposed of natural and/or synthetic fibers. The bodyside liner can becomposed of a substantially hydrophobic material, and the hydrophobicmaterial can, optionally, be treated with a surfactant or otherwiseprocessed to impart a desired level of wettability and hydrophilicity.For example, the material can be surface treated with about 0.45 weightpercent of a surfactant mixture comprising Ahcovel N-62 from HodgsonTextile Chemicals of Mount Holly, N.C., U.S.A. and Glucopan 220UP fromHenkel Corporation of Ambler, Pa. in an active ratio of 3:1. Thesurfactant can be applied by any conventional means, such as spraying,printing, brush coating or the like. The surfactant can be applied tothe entire bodyside liner 42 or can be selectively applied to particularsections of the bodyside liner, such as the medial section along thelongitudinal center line.

[0055] A suitable liquid permeable bodyside liner 42 is a nonwovenbicomponent web having a basis weight of about 27 gsm. The nonwovenbicomponent can be a spunbond bicomponent web, or a bonded cardedbicomponent web. Suitable bicomponent fibers include apolyethylene/polypropylene bicomponent fiber available from CHISSOCorporation, Osaka, Japan. In this particular bicomponent fiber, thepolypropylene forms the core and the polyethylene forms the sheath ofthe fiber. Other fiber orientations are possible, such as multi-lobe,side-by-side, end-to-end, or the like. The outer cover 40, bodysideliner 42 and other materials used to construct the pants 20 can compriseelastomeric or nonelastomeric materials.

[0056] The absorbent body 44 (FIG. 3) is positioned between the outercover 40 and the bodyside liner 42, which can be joined together by anysuitable means such as adhesives, ultrasonic bonds, thermal bonds, orthe like. The absorbent body 44 can be any structure which is generallycompressible, conformable, non-irritating to the child's skin, andcapable of absorbing and retaining liquids and certain body wastes, andmay be manufactured in a wide variety of sizes and shapes, and from awide variety of liquid absorbent materials commonly used in the art. Forexample, the absorbent body 44 can suitably comprise a matrix ofhydrophilic fibers, such as a web of cellulosic fluff, mixed withparticles of a high-absorbency material commonly known as superabsorbentmaterial. In a particular embodiment, the absorbent body 44 comprises amatrix of cellulosic fluff, such as wood pulp fluff, and superabsorbenthydrogel-forming particles. The wood pulp fluff can be exchanged withsynthetic, polymeric, meltblown fibers or short cut homofil bicomponentsynthetic fibers and natural fibers. The superabsorbent particles can besubstantially homogeneously mixed with the hydrophilic fibers or can benonuniformly mixed. The fluff and superabsorbent particles can also beselectively placed into desired zones of the absorbent body 44 to bettercontain and absorb body exudates. The concentration of thesuperabsorbent particles can also vary through the thickness of theabsorbent body 44. Alternatively, the absorbent body 44 can comprise alaminate of fibrous webs and superabsorbent material or other suitablemeans of maintaining a superabsorbent material in a localized area.

[0057] Suitable superabsorbent materials can be selected from natural,synthetic, and modified natural polymers and materials. Thesuperabsorbent materials can be inorganic materials, such as silicagels, or organic compounds, such as crosslinked polymers, for example,sodium neutralized polyacrylic acid. Suitable superabsorbent materialsare available from various commercial vendors, such as Dow ChemicalCompany located in Midland, Mich., U.S.A., and Stockhausen GmbH & Co.KG, D-47805 Krefeld, Federal Republic of Germany. Typically, asuperabsorbent material is capable of absorbing at least about 10 timesits weight in water, and suitably is capable of absorbing more thanabout 25 times its weight in water.

[0058] In one embodiment, the absorbent body 44 comprises a blend ofwood pulp fluff and superabsorbent material. One preferred type of pulpis identified with the trade designation CR1654, available from U.S.Alliance, Childersburg, Ala., U.S.A., and is a bleached, highlyabsorbent sulfate wood pulp containing primarily soft wood fibers andabout 16 percent hardwood fibers. As a general rule, the superabsorbentmaterial is present in the absorbent body 44 in an amount of from 0 toabout 90 weight percent based on total weight of the absorbent assembly.The absorbent body 44 suitably has a density within the range of about0.10 to about 0.35 grams per cubic centimeter. The absorbent body 44 mayor may not be wrapped or encompassed by a suitable tissue wrap that mayhelp maintain the integrity and/or shape of the absorbent assembly.

[0059] The central absorbent assembly 32 can also incorporate othermaterials or components designed primarily to receive, temporarilystore, and/or transport liquid along the mutually facing surface withthe absorbent body 44, thereby maximizing the absorbent capacity of theabsorbent assembly. One suitable additional component is commonlyreferred to as a surge layer (not shown) and comprises a material havinga basis weight of about 50 to about 120 grams per square meter, and moreparticularly comprises a through-air-bonded-carded web of a homogenousblend of 60 percent 3 denier type T-256 bicomponent fiber comprising apolyester core/polyethylene sheath and 40 percent 6 denier type T-295polyester fiber, both commercially available from Kosa Corporation ofSalisbury, N.C., U.S.A.

[0060] As noted previously, the illustrated training pants 20 have frontand back side panels 34 and 134 disposed on each side of the absorbentassembly 32. The side panels 34, 134 can be permanently bonded alongseams 66 to the central absorbent assembly 32 in the respective frontand back waist regions 22 and 24. More particularly, as seen best inFIGS. 2 and 3, the front side panels 34 can be permanently bonded to andextend transversely outward beyond the side edges 47 of the absorbentassembly 32 in the front waist region 22, and the back side panels 134can be permanently bonded to and extend transversely outward beyond theside edges of the absorbent assembly in the back waist region 24. Theside panels 34 and 134 may be bonded to the absorbent assembly 32 usingattachment means known to those skilled in the art such as adhesive,thermal or ultrasonic bonding. Alternatively, the side panels 34 and 134can be formed as an integral portion of a component of the absorbentassembly 32. For example, the side panels can comprise a generally widerportion of the outer cover 40, the bodyside liner 42, and/or anothercomponent of the absorbent assembly 32. The front and back side panels34 and 134 can be permanently bonded together or be releasably connectedwith one another such as by the fastening system 80 of the illustratedembodiment.

[0061] The front and back side panels 34, 134 each have an outer edge 68spaced laterally from the seam 66, a leg end edge 70 disposed toward thelongitudinal center of the training pants 20, and a waist end edge 72disposed toward a longitudinal end of the training pants. The leg endedge 70 and waist end edge 72 extend from the side edges 47 of theabsorbent assembly 32 to the outer edges 68. The leg end edges 70 of theside panels 34 and 134 form part of the side edges 36 of the trainingpants 20. The leg end edges 70 of the illustrated embodiment aresuitably curved and/or angled relative to the transverse axis 49 toprovide a better fit around the wearer's legs. However, it is understoodthat only one of the leg end edges 70 may be curved or angled, such asthe leg end edge of the back waist region 24, or neither of the leg endedges may be curved or angled, without departing from the scope of thisinvention. The waist end edges 72 are suitably parallel to thetransverse axis 49. The waist end edges 72 of the front side panels 34form part of the front waist edge 38 of the training pants 20, and thewaist end edges 72 of the back side panels 134 form part of the backwaist edge 39 of the pants.

[0062] The side panels 34, 134 suitably, although not necessarily,comprise an elastic material capable of stretching in a directiongenerally parallel to the transverse axis 49 of the training pants 20.Suitable elastic materials, as well as one process of incorporatingelastic side panels into training pants, are described in the followingU.S. Pat. No. 4,940,464 issued Jul. 10, 1990 to Van Gompel et al.; U.S.Pat. No. 5,224,405 issued Jul. 6, 1993 to Pohjola; U.S. Pat. No.5,104,116 issued Apr. 14, 1992 to Pohjola; and U.S. Pat. No. 5,046,272issued Sep. 10, 1991 to Vogt et al.; all of which are incorporatedherein by reference. In particular embodiments, the elastic material maycomprise a stretch-thermal laminate (STL), a neck-bonded laminate (NBL),a reversibly necked laminate, or a stretch-bonded laminate (SBL)material. Methods of making such materials are well known to thoseskilled in the art and described in U.S. Pat. No. 4,663,220 issued May5, 1987 to Wisneski et al.; U.S. Pat. No. 5,226,992 issued Jul. 13, 1993to Morman; European Patent Application No. EP 0 217 032 published onApr. 8, 1987 in the name of Taylor et al.; and PCT application WO01/88245 in the name of Welch et al.; all of which are incorporatedherein by reference. Alternatively, the side panel material may compriseother woven or nonwoven materials, such as those described above asbeing suitable for the outer cover 40 or bodyside liner 42; mechanicallypre-strained composites; or stretchable but inelastic materials.

[0063] The fastening system 80 comprises laterally opposite firstfastening components 82 adapted for refastenable engagement tocorresponding second fastening components 84. In one embodiment, a frontor outer surface of each of the fastening components 82, 84 comprises aplurality of engaging elements. The engaging elements of the firstfastening components 82 are adapted to repeatedly engage and disengagecorresponding engaging elements of the second fastening components 84 toreleasably secure the pants 20 in its three-dimensional configuration.

[0064] The fastening components 82, 84 can comprise any refastenablefasteners suitable for absorbent articles, such as adhesive fasteners,cohesive fasteners, mechanical fasteners, or the like. In particularembodiments the fastening components comprise mechanical fasteningelements for improved performance. Suitable mechanical fasteningelements can be provided by interlocking geometric shaped materials,such as hooks, loops, bulbs, mushrooms, arrowheads, balls on stems, maleand female mating components, buckles, snaps, or the like.

[0065] In the illustrated embodiment, the first fastening components 82comprise loop fasteners and the second fastening components 84 comprisecomplementary hook fasteners. Alternatively, the first fasteningcomponents 82 may comprise hook fasteners and the second fasteningcomponents 84 may comprise complementary loop fasteners. In anotherembodiment, the fastening components 82, 84 can comprise interlockingsimilar surface fasteners, or adhesive and cohesive fastening elementssuch as an adhesive fastener and an adhesive-receptive landing zone ormaterial; or the like. Although the training pants 20 illustrated inFIG. 1 show the back side panels 134 overlapping the front side panels34 upon connection thereto, which is convenient, the training pants 20can also be configured so that the front side panels overlap the backside panels when connected. One skilled in the art will recognize thatthe shape, density and polymer composition of the hooks and loops may beselected to obtain the desired level of engagement between the fasteningcomponents 82, 84. A more aggressive hook material may comprise amaterial with a greater average hook height and/or a greater percentageof directionally-aligned hooks.

[0066] Loop fasteners typically comprise a fabric or material includinga plurality of loop members. The loop material can be formed of anysuitable material, such as acrylic, polyamide, polyethylene,polypropylene or polyester, and can be formed by methods such as warpknitting, stitch bonding or needle punching. Loop materials can alsocomprise any fibrous structure capable of entangling or catching hookmaterials, such as carded, spunbonded or other nonwoven webs orcomposites, including elastomeric and nonelastomeric composites.Suitable loop materials are available from Guilford Mills, Inc.,Greensboro, N.C., U.S.A. under the trade designation No. 36549. Anothersuitable loop material can comprise a pattern un-bonded web as disclosedin co-assigned U.S. Pat. No. 5,858,515 issued Jan. 12, 1999 to Stokes etal. incorporated herein by reference. The loop material may be securedto a base, or backing structure and the composite then secured to thepants 20, or the loop material may be secured directly to the pants sothat the pair of pants serves as a backing for the loop material, or theloop material may be formed integrally with the pants, such as byconstructing one or more layers or surfaces of the back side panels 134from a loop material.

[0067] Hook fasteners typically comprise a fabric or material having abase or backing structure and a plurality of hook members extendingupwardly from at least one surface of the backing structure. It shouldbe understood that the term “hook” as used in reference to the hookmembers is non-limiting in the sense that the engaging elements of thehook fasteners may comprise shapes such as hooks, “T's”, “mushrooms” orany other shape so long as they are adapted to releasably engage theloop fasteners so as to provide a secure, but non-destructivelyreleasable engagement. In contrast to the loop fasteners which suitablycomprise a flexible fabric, the hook material may advantageouslycomprise a resilient material to minimize unintentional disengagement ofthe fastening components 82, 84 as a result of the hook materialbecoming deformed and catching on clothing or other items. The term“resilient” as used herein refers to an interlocking material having apredetermined shape and the property of the interlocking material toresume the predetermined shape after being engaged and disengaged from amating, complementary interlocking material.

[0068] Suitable hook material can be molded or extruded from nylon,polypropylene, polyethylene or another suitable material. Suitablesingle-sided hook materials for the fastening components are availablefrom commercial vendors such as Velcro Industries B.V., Amsterdam,Netherlands or affiliates thereof, identified as Velcro HTH-829, whichhas a thickness of about 0.9 millimeters (35 mils) and HTH-851, whichhas a thickness of about 0.5 millimeters (20 mils); and Minnesota Mining& Manufacturing Co., St. Paul, Minn. U.S.A., including specificmaterials identified as CS-600. As with the loop fastener, it isunderstood that the hook material may formed integrally with the pants20, and more particularly with the side panels 34, without departingfrom the scope of this invention.

[0069] With particular reference to FIG. 3, the first fasteningcomponents 82 (e.g., the loop fasteners) are disposed on the innersurface 28 of the back side panels 134, and are suitably positionedadjacent the outer edges 68 of the back side panels 134. The secondfastening components 84 (e.g., the hook fasteners) are disposed on theouter surface 30 of the front side panels 34 adjacent the outer edges 68thereof as shown in FIG. 2, and are suitably sized to receive the firstfastening components 82.

[0070] It is understood that the fastening components 82, 84 may alsoextend laterally out beyond the outer edges 68 of the side panels 134,34. Where the first fastening components 82 comprise loop fastenersdisposed on the inner surface 28 and the second fastening components 84comprise hook fasteners disposed on the outer surface 30, the firstfastening components can be sized larger than the second fasteningcomponents to ensure coverage of the rigid, outwardly-directed hooks.

[0071] The fastening components 82, 84 of the illustrated embodimentsare rectangular, although they may alternatively be square, round, oval,curved or other suitable shapes. In particular embodiments, each of thefastening components 82, 84 has a length aligned generally parallel tothe longitudinal axis 48 of the training pants 20 and a width alignedgenerally parallel to the transverse axis 49 of the training pants. Fora child of about 9 to about 15 kilograms (20-30 pounds), for example,the length of the fastening components 82, 84 is desirably from about 50to about 130 mm, such as about 100 mm, and the width is desirably fromabout 5 to about 30 mm, such as about 10 mm. In particular embodiments,the fastening components 82, 84 can have a length-to-width ratio ofabout 2 or greater, such as about 2 to about 25, and more particularlyabout 5 or greater, such as about 5 to about 8. For other embodimentssuch as for adult products, it may be desirable for one or more of thefastening components to comprise a plurality of relatively smallerfastening elements. In that case, a fastening component or individualfastening elements may have an even smaller length-to-width ratio, forexample, of about 2 or less, and even about 1 or less.

[0072] The fastening components 84, 82 are suitably secured to therespective side panels 34, 134 by mechanical bonding. As used herein,mechanical bonding refers to non-adhesive bonding, such as by theapplication of pressure, ultrasonic energy, heat, laser energy or anyother suitable form of energy which joins the fastening components tothe side panels. It is understood that the fastening components 84, 82may be adhered, such as by adhesive or cohesive means, to the respectiveside panels 34, 134 in addition to being mechanically bonded thereto, orthe fastening components may only be mechanically bonded to the sidepanels, without departing from the scope of this invention. Where afastening component 82, 84 is formed integrally with the respective sidepanel 134, 34, mechanical bonding may be omitted or may comprisemechanically bonding the fastener material layer of the side panel toone more other layers or surfaces of the side panel.

[0073] As shown in FIG. 1, when the fastening components 82, 84 arereleasably engaged, the side edges 36 of the training pants 20 in thecrotch region 26 define the leg openings 52, and the waist edges 38 and39 including the waist end edges 72 of the side panels 34, 134 definethe waist opening 50. For improved formation of the leg openings 52, itcan be desirable in some embodiments for the front side panels 34 to belongitudinally spaced from the back side panels 134 as shown in FIGS. 2and 3. For example, the front side panels 34 can be longitudinallyspaced from the back side panels 134 by a distance equal to about 20percent or greater, particularly from about 20 to about 60 percent, andmore particularly from about 35 to about 50 percent, of the overalllength of the pants 20.

[0074] When engaged, the fastening components 82, 84 of the illustratedembodiment define refastenable engagement seams 88 (FIG. 1) whichdesirably although not necessarily extend substantially the entiredistance between the waist opening 50 and the leg openings 52. Morespecifically, the engagement seams 88 can cover about 70 to 100 percent,and particularly about 85 to about 95 percent, of the distance betweenthe waist opening 50 and each leg opening 52, which distance is measuredparallel to the longitudinal axis 48. To construct the engagement seams88 to extend substantially the entire distance between the waist and legopenings 50 and 52, the fastening components 82, 84 can be formed tocover about 70 to 100 percent, and more particularly about 85 to about95 percent, of the distance between the waist end edge 70 and the legend edge 72 of the side panels 34, 134. In other embodiments, thefastening components can comprise a plurality of smaller fasteningelements (not shown) covering a smaller portion of the distance betweenthe waist opening 50 and the leg openings 52, for example, about 20 toabout 70 percent, but spaced apart to span a larger percentage of thedistance between the waist opening and the leg openings.

[0075] For the engagement seams 88 to be located at the sides of thewearer, it can be particularly desirable for the transverse distancebetween the fastening components 82 of the back side panels 134 to besubstantially equal to the transverse distance between the fasteningcomponents 84 of the front side panel 134. The transverse distancebetween each respective set of fastening components 82, 84 is measuredparallel to the transverse axis 49 between the longitudinal center linesof the respective fastening components, measured with the side panels34, 134 in an unstretched condition. Alternatively, the lateral spacingbetween the fastening components 82 may be greater or less than thelateral spacing between the fastening components 84. It is alsocontemplated that fastening components 82 (and/or the fasteningcomponents 84) may not be laterally opposite each other, or may be onlypartially laterally opposite each other, such as by being offsetlongitudinally.

[0076]FIG. 4 illustrates one embodiment of apparatus, generallyindicated at 100, for making a continuous stream of partially assembled,discrete training pants 102. The method and apparatus described hereinin relation to FIG. 4 is particularly suited to manufacture trainingpants 102 which are similar to the pants 20 illustrated in FIG. 1.However, it understood that the particular components of the apparatus100 may vary depending on the specific type of absorbent article beingmanufactured.

[0077] The various components of the training pants 102 can be connectedtogether by any means known to those skilled in the art such as, forexample, adhesive, thermal and/or ultrasonic bonds. Desirably, most ofthe components are connected using ultrasonic bonding for improvedmanufacturing efficiency and reduced raw material costs. Certain articlemanufacturing equipment which is readily known and understood in theart, including frames and mounting structures, transport conveyors,transfer rolls, guide rolls, tension rolls, and the like, have not beenshown in FIG. 4. Suitable absorbent supply mechanisms, web unwinds,conveyor systems, registration systems, drive systems, control systemsand the like, for use with the present process are disclosed in U.S.patent application Ser. No. 09/855,484 entitled “Methods for MakingGarments with Fastening Components” and filed May 15, 2001, and U.S.Pat. No. 5,766,389 issued Jun. 16, 1998 to Brandon et al., which arehereby incorporated herein by reference.

[0078] In the illustrated embodiment, a continuous supply of material104 used to form the bodyside liner 42 of the pants 102 is provided froma supply source 106. The supply source 106 can comprise for example anystandard unwind mechanism, which generally includes a pair of spindles,a festoon assembly, and a dancer roll for providing bodyside linermaterial 104 at a desired speed and tension.

[0079] Various components of the pants 20 can be disposed on and/orbonded to the bodyside liner material 104 as the material travels in amachine direction identified by arrow 108. In particular, a surge layercan be provided at an application station 110 and disposed on and/orbonded to the bodyside liner material 104. The surge layer can compriseeither a continuous web or discrete sheets. Additionally, a containmentflap module 112 can be provided downstream of the supply source 106 forattaching pre-assembled containment flaps to the bodyside liner material104. As various components are added in the assembly section 100, acontinuously moving product assemblage 113 is formed. The continuouslymoving product assemblage 113 defines a longitudinal center line 105(FIG. 5) which can correspond to the machine center line. The productassemblage 113 will be cut downstream to form the partially assembled,discrete training pants 102.

[0080] Absorbent bodies 114 can be provided from a suitable supplysource 115. The supply source 115 can be any conventional mechanism forsupplying the absorbent bodies 114. Generally, a conventional supplysource can include a hammermill for forming fluff fibers and, ifdesired, for providing an enclosure for mixing superabsorbent materialwith the fluff fibers, and then depositing the fluff and superabsorbentmaterial on a forming drum having a desired absorbent design. Theindividual absorbent bodies 114 can be disposed intermittently on thecontinuously moving bodyside liner material 104, one for each pair oftraining pants. The position of the absorbent bodies 114 can beregistered with the position of the surge layer, if employed. Theabsorbent bodies 114 can be bonded to one or more other components usingadhesives or other suitable means. Alternatively, composite absorbentmaterials can be fed into the converting process from rolls orcompressed packages, such as festooned bales.

[0081] Continuous webs of material 116 used to form the side panels 34and 134 can be provided from suitable supply sources 117. The supplysources 117 can comprise one or more standard unwind mechanisms. Theside panel material 116 can be cut into individual generally rectangularstrips 118, also referred to as side panel strips 118, and positionedpartially on the bodyside liner material 104 using an applicator device120. In the cross machine direction, the individual strips 118 desirablyextend laterally outward from the bodyside liner material 104 (see FIG.5) and overlap the bodyside liner material by an amount such as about 2cm or more to permit bonding of the strips to the bodyside liner and/orthe containment flap material. In the machine direction 108, theposition of the strips 118 can be registered relative to the absorbentbodies 114 so that the product assemblage 113 can be cut between theabsorbent bodies with each strip 118 of side panel material 116 formingboth a front side panel 34 and a back side panel 134 of consecutivearticles 102.

[0082] One suitable applicator device 120 is disclosed in U.S. Pat. Nos.5,104,116 issued Apr. 14, 1992 and U.S. Pat. No. 5,224,405 issued Jul.6, 1993 both to Pohjola, which are incorporated herein by reference. Theapplicator device 120 can comprise a cutting assembly 122 and arotatable transfer roll 124. The cutting assembly 122 employs arotatable knife roll 126 and a rotatable vacuum anvil roll 128 to cutindividual strips 118 from the continuous side panel material 116. Thestrips 118 cut by a blade on the knife roll 126 can be maintained on theanvil roll 128 by vacuum and transferred to the transfer roll 124.

[0083] The rotatable transfer roll 124 can comprise a plurality ofrotatable vacuum pucks 130. The vacuum pucks 130 receive the strips 118of material 116 from the cutting assembly 122 and rotate and transferthe strips to the continuously moving bodyside liner material 104. Whenthe strips 118 are positioned as desired relative to the bodyside linermaterial 104, the strips are released from the pucks 130 byextinguishing the vacuum in the pucks. The pucks 130 then continue torotate toward the cutting assembly 122 to receive other strips. Theresulting product assemblage 113 thus has a plurality of pairs oftransversely opposite side panel strips 118 whereby the side panelstrips extend transversely outward from the longitudinal center line 105of the product assemblage.

[0084] A continuous supply of material 140 used to form the outer cover40 can be provided from a supply roll 142 or other suitable source. Theouter cover material 140 can be transported over a laminator roll 144and married with the bodyside liner material 104. The absorbent bodies114 are thereby sandwiched between the continuous materials 104 and 140.The inward portions of the strips 118 of side panel material 116 canalso be disposed between the bodyside liner material 104 and the outercover material 140. Alternative configurations for attaching the sidepanel material 116 are disclosed by Van Gompel et al. Various componentssuch as leg elastics 58 or waist elastics 54 and 56 can be bonded to theouter cover material 140 at an application station 146 prior to unitingthe bodyside liner and outer cover materials 104, 140. Alternatively,leg elastics or waist elastics can be initially bonded to the bodysideliner material 104 or another material.

[0085] Bonding devices 148 such as ultrasonic bonding devices can beemployed downstream of the laminator roll 144 to bond the bodyside linermaterial 104, side panel material 116 and outer cover material 140. Forexample, these materials can be transported between a conventionalrotary ultrasonic horn and anvil roll. Suitable ultrasonic bondingdevices are described in U.S. Pat. No. 5,110,403 to Ehlert, which isincorporated herein by reference. Alternatively, the ultrasonic horn maybe a stationary ultrasonic horn as is also known to those skilled in theart. Other suitable ultrasonic horns and ultrasonic bonders arecommercially available from Branson Sonic Power Company, Danbury, ConnU.S.A. The bonding devices 148 could otherwise be a thermal or adhesivebonder as are well known.

[0086] The continuously moving product assemblage 113 next advances to afastener application station 150 where fastening components 82, 84 arepositioned on and bonded to the strips 118 of side panel material 116.The location of the fastening components on the composite is a functionin part of the configuration of the apparatus 100. The illustratedapparatus 100 is configured so that the upwardly facing major surface ofthe product assemblage 113 will become the outer surface 30 of thetraining pants 20 and the downwardly facing major surface will becomethe inner surface 28. Moreover, the illustrated apparatus 100 isconfigured to produce training pants 102 having the front waist region22 of a leading pair of pants connected to the back waist region 24 of atrailing pair as shown in FIG. 5.

[0087] The process could alternatively employ any combination ofdifferent orientations. For example, the upwardly facing surface of theproduct assemblage 113 could form the inner surface 28 of finishedarticles. Additionally, or alternatively, the back waist region 24 of aleading pair of pants 102 can be connected to the front waist region 22of the trailing pair of pants, or the pants can be arranged in afront-to-front/back-to-back relationship. Still alternatively, theapparatus 100 could be constructed as a cross-machine direction processwherein the longitudinal axis 48 of each pair of pants could beperpendicular to the machine direction 108 during part or all of theassembly process.

[0088] The location of the fastening components 82, 84 in thisembodiment is best illustrated in FIG. 5, which shows a portion of theproduct assemblage 113 moving in the direction of arrow 108 immediatelyfollowing application of the fastening components 82, 84 to the productassemblage. Each individual strip 118 of side panel material 116 definesa leading edge 152, a trailing edge 154, a distal edge 156 and aninterior edge 158. A dashed line 159 illustrates the location at whichthe product assemblage 113 can subsequently be cut to provide thediscrete training pants 20. Based on the illustrated orientation of thecontinuously moving product assemblage 113, the first fasteningcomponents 82 can be positioned on and bonded to the underside of thestrips 118 corresponding to the back side panels 134 and the secondfastening components 84 can be positioned on and bonded to the topsurface of the strips corresponding to the front side panels 34.

[0089] The first fastening components 82 are desirably disposed onopposite sides of the longitudinal center line 105 at selected crossmachine direction locations, and the second fastening components 84 aredesirably disposed on opposite sides of the longitudinal center line 105at the same selected cross machine direction locations as the firstfastening components 82. For purposes of the present invention, the term“cross machine direction location” refers to a location spaced from themachine center line, measured perpendicular thereto.

[0090] With reference again to FIG. 4, continuous webs of secondfastener material 160 used to form the second fastening components 84can be provided from supply rolls 162 or other suitable sources. Thesecond fastener material 160 can be cut into individual second fasteningcomponents by cutting assemblies 164 or other suitable devices. Theillustrated cutting assemblies 164 include rotatable knife rolls 166,rotatable vacuum anvil rolls 167, and rotatable backing rolls 168. Thecontinuous second fastener materials 160 can be cut by blades on theknife rolls 166, maintained on the anvil rolls 167 by vacuum, anddisposed on the top surfaces of the strips 118 of side panel material116.

[0091] Similarly, continuous webs of first fastener material 170 used toform the first fastening components 82 can be provided from supply rolls172 or other suitable sources. The first fastener material 170 can becut into individual first fastening components 82 by cutting assemblies174 or other suitable devices. The illustrated cutting assemblies 174include rotatable knife rolls 176, rotatable vacuum anvil rolls 177, androtatable backing rolls 178. The continuous first fastener material webs170 can be cut by blades on the knife rolls 176, maintained on the anvilrolls 177 by vacuum, and disposed on the undersides of the strips 118 ofside panel material 116.

[0092] With the fastening components 82, 84 positioned on the side panelstrips 118, the product assemblage 113 is further transported in themachine direction past apparatus, generally indicated at 180, of thepresent invention for mechanically bonding and cutting the pants 102 ofthe assemblage, and more particularly to mechanically bond the firstfastener material 170 and the second fastener material 160 to the sidepanel strips 118, and for cutting away portions of the side panel strips118 to provide the angled and/or curved leg end edges 70 of the frontand back side panels 34, 134 of the pants. The apparatus 180 aretransversely spaced from each other on opposite sides of thelongitudinal centerline 105 to mechanically bond and cut the side panels34, 134 extending outward from each side edge 47 of the centralabsorbent assembly 32. The fastening components 82, 84 can be maintainedon the side panel strips 118 as the product assemblage 113 istransported to the mechanical bonding and cutting apparatus 180 usingsuitable vacuum devices (not shown), or they can be attached to the sidepanel strips at the fastener application station 150 with adhesivebonds.

[0093] As shown in FIG. 6, each mechanical bonding and cutting apparatus180 (only one of which is shown in FIG. 6, the other being ofsubstantially the same construction) comprises an anvil roll 210(broadly, a first member of the mechanical bonding and cuttingapparatus) and a bonding roll 216 (broadly, a second member of themechanical bonding and cutting apparatus) positioned in opposed,parallel relationship with the anvil roll to define a nip 219therebetween. The anvil roll 210 is rotatably mounted on suitablesupport structure 217, such as by conventional bearings (not shown), forrotation about its rotation axis in the direction indicated by arrow 212between a bonding mode in which the product assemblage 113 is subjectedto mechanical bonding as it passes through the nip 219 and a cuttingmode in which the product assemblage is subjected to a cutting operationas it passes through the nip. As is shown in FIG. 6, rotation of theanvil roll 210 in the direction indicated by arrow 212 corresponds totangential movement of the anvil roll at the nip 219 generally in themachine direction 108 in which the product assemblage is transported.

[0094] It is understood that the anvil roll 210 and bonding roll 216 maybe slightly spaced from each other at the nip throughout the fullrevolution of the anvil roll, or they may contact each other at the nipthroughout all or part of a full revolution of the anvil roll.

[0095] In general, the anvil roll 210 may be made from any metal havingsuitable mechanical properties. For example, in one embodiment the anvilroll 210 is constructed of hardened steel. The width of the anvil roll210 of the illustrated embodiment is suitably equal to or less than thetransverse outward extension of the side panel strips 118 from the sideedges 47 of the central absorbent assembly 32. As an example, the anvilroll 210 shown in FIG. 6 has a width of about 2.75 inches (about 7 cm).In this manner, mechanical bonding and cutting of the pants 102 of theassemblage 113 is limited to the side panel strips 118 thereof. However,it is understood that the anvil roll width may be smaller, or it may belarger so that upon transporting the product assemblage 113 in themachine direction 108, other (or additional) components of the productassemblage 113 pass through the nip 219 defined by the anvil roll 210and bonding roll 216 without departing from the scope of this invention.

[0096] In one embodiment, the bonding roll 216 comprises a rotaryultrasonic horn (not shown). Representative examples of rotaryultrasonic horns which can be used are described in commonly assignedU.S. Pat. No. 5,096,532 to Neuwirth et al. and U.S. Pat. No. 5,110,403to Ehlert, which are herein incorporated by reference. In general, therotary ultrasonic horn may be made from any metal having suitableacoustical and mechanical properties. Suitable metals include aluminum,nickel alloys, nickel-copper alloys, titanium and some alloy steels.Alternatively, the ultrasonic horn may be a stationary ultrasonic hornas is also known to those skilled in the art. It is also contemplatedthat the second member of the mechanical bonding and cutting apparatusmay be other than a bonding roll 216, such as a plate or other suitablestructure forming a nip with the anvil roll 210, and remain within thescope of this invention.

[0097] The anvil roll 210 has a circumferential outer surface 220configured for intermittent mechanical bonding of the fastener materials160, 170 and the side panel strips 118 together and cutting of the sidepanel strips to form the desired leg end edge 70 configurations uponrotation of the anvil roll. As representatively illustrated in FIGS. 7and 8, a circumferential segment of the outer surface 220 of the anvilroll 210 broadly defines a bonding segment, generally indicated at 230,thereof and comprises a plurality of projections 222 extending outwardtherefrom. The projections 222 of the illustrated embodiment are groupedwithin a generally rectangular region defining a width of the bondingsegment 230 that is less than the width of the anvil roll outer surface220, and more particularly corresponds generally to the width of thefastening components 160. 170 positioned on the side panel strips 118.However, it is understood that the width of the bonding segment 230 maybe greater than or less than the width of the fastener components 160,170. It is also contemplated that the width of the bonding segment 230may be substantially equal to the width of the anvil roll outer surface220 (e.g., the bonding segment may span the width of the anvil rollouter surface) without departing from the scope of this invention.

[0098] In the laid flat illustration of the anvil roll 210 in FIG. 7,the anvil roll outer surface 220 is bisected generally centrally of thecontinuous bonding segment 230 to correspond to the location (159 inFIG. 5) at which a trailing edge of one pair of the pants 102 of theassemblage 113 is connected to the leading edge of the next pair ofpants. The length of the continuous bonding segment 230 is such that aportion (e.g., about one-half, or one end of the bisected bondingsegment of FIG. 7) of the length of the bonding segment can be used formechanically bonding the fastening component 84 to the side panel strip118 corresponding to the front side panel 34 of one pair of pants 102 ofthe assemblage 113. The remaining length (e.g., the other end of thebisected bonding segment 230 of FIG. 7)of the bonding segment can beused for mechanically bonding the fastening component 82 to the sidepanel strip 118 corresponding to the back side panel 134 of a trailingpair of pants 102 of the assemblage 113. However, it is understood thatthe outer surface 220 of the anvil roll 210 may comprise two or morediscrete (e.g. circumferentially and/or transversely spaced) bondingsegments without departing from the scope of this invention. It is alsocontemplated that the bonding segment 230 may be sized for mechanicallybonding only one fastening component 82, 84 to the side panel strip 118as shown in FIG. 10 and described later herein.

[0099] The bonding segment projections 222 of the illustrated embodimentare generally circular pins having a diameter which tapers inward towardits outer tip. For example, the pins shown in FIGS. 8 and 9 each have abase diameter of about 0.86 inches (e.g., about 2.18 mm), and an outertip diameter of about 0.48 inches (e.g., about 1.22 mm). However, theprojections 222 can be sized in cross-section other than as set forthabove, and/or they may have other cross-sectional shapes, such assquare, S-shape, hexagon or other useful shapes. As is also shown inFIGS. 8 and 9, the pins are formed integrally with a platform 232 formedon the anvil roll outer surface whereby the platform extends radiallyoutward beyond a reference outer surface 234 or reference outer diameterof the anvil roll. The pins extend outward from the platform 232approximately 0.125 inches (e.g., about 3.175 mm). The platform heightis approximately 0.0765 inches (e.g., about 1.943 mm) above (e.g.,outward of) of the reference outer surface 234.

[0100] The projections 222 defining the bonding segment 230 mechanicallybond the fastening components 160, 170 to the side panel strips 118 in apattern of discrete bond points as the side panel strips pass throughthe nip 219 in the bonding mode of the apparatus. Alternatively, thebonding segment 230 of the anvil roll outer surface 220 may be definedby a plurality of depressions (not shown) disposed therein such that themechanical bonding forms a continuous bond pattern on the side panelstrips 118. The projections 222 may be arranged in any repeating orarbitrary pattern depending upon the desired bond pattern. Particularultrasonic bond patterns comprising bonds which are compatible with themechanical fastening of materials are disclosed in co-assigned U.S. Pat.No. 5,660,666 issued Aug. 26, 1997 to Dilnik et al., and commonlyassigned U.S. application Ser. No. 10/038675 to Koele, et al., both ofwhich are incorporated herein by reference.

[0101] Still referring to FIGS. 6 and 7, the circumferential outersurface 220 of the anvil roll 210 further comprises a cutting segment,generally indicated at 236, for cutting the product assemblage, and moreparticularly for cutting the side panel strips 118, in the cutting modeof the apparatus. At least a portion of the cutting segment 236, andmore suitably the full circumferential extent of the cutting segment, isdiscrete from the bonding segment 230, such as by being located at adifferent circumferential location of the anvil roll outer surface 220than the bonding segment, so that in the bonding mode of the apparatusthe anvil roll 210 is oriented such that the bonding segment of theouter surface defines the nip 219 together with the bonding roll 216 andthe cutting segment is external of the nip and in the cutting mode ofthe apparatus the anvil roll is oriented such that the cutting segment236 defines the nip together with the bonding roll and the bondingsegment is external of the nip.

[0102] The cutting segment 236 of the illustrated embodiment comprises ablade 238 projecting outward of the anvil roll outer surface 220 andextending continuously along a portion of the circumference thereof. Itis understood, however, that the cutting segment 236 may comprise aserrated blade or it may comprise two or more blades in closely spacedend-to-end relationship with each other, without departing from thescope of this invention. The blade 238 also extends transversely acrossthe anvil roll outer surface 220 (e.g., transverse to the circumferenceof the anvil roll 210) for transversely cutting each pair of pants 102of the product assemblage 113, and more particularly each of the sidepanel strips 118. For example, in the illustrated embodiment the blade238 extends transversely across the entire width of the anvil roll outersurface 220. However, the blade 238 may extend transversely across onlya portion of the width of the outer surface 220 of the anvil roll 210without departing from the scope of this invention.

[0103] More particularly, the blade 238 of the cutting segment 236 shownin FIG. 7 extends both transversely and circumferentially on the anvilroll outer surface 220 generally along a first portion 240 of thecutting segment to define a first cutting pattern of the blade. Thefirst cutting pattern is shaped to cut a portion of the side panel strip118 to form the curved leg end edge 70 of the back side panel 134 of thecompleted training pants 102. A transition portion 242 of the cuttingblade 238 extends from the first portion 240 thereof circumferentiallyon the anvil roll outer surface 220 to a second portion 244 of thecutting blade which extends transversely and circumferentially on theouter surface to define a second cutting pattern of the blade. Thesecond cutting pattern is shaped to cut a portion of the sequentiallynext side panel strip 118 to form the curved leg end edge 70 of thefront side panel 34 of the completed training pants 102.

[0104] While the anvil roll outer surface 220 shown in FIG. 7 comprisesa single cutting segment 236 configured to cut each of the side panelstrips 118 corresponding respectively to the front and back side panels34, 134 of the completed training pants 102, it is understood that thecutting segment may be configured for cutting only one of the side panelstrips whereby the other side panel strip remains uncut as theassemblage 113 of training pants pass the mechanical bonding and cuttingapparatus 180. It is also understood that the anvil roll outer surface220 may comprise two or more discrete cutting segments as shown in FIG.11 and described later herein.

[0105] As seen best in FIG. 9, the blade 238 is generally triangular incross-section. However, it is understood that alternativecross-sectional shapes suitable for cutting material webs may be used.The blade 238 suitably projects outward of the anvil roll outer surface220 (e.g., relative to the reference surface, or reference diameter)further than the outer ends of the projections 222 of the bondingsegment 230. For example, the blade 238 of the illustrated embodimentprojects outward of the reference surface, or reference diameter,approximately 0.2 inches (approximately 0.5 cm).

[0106] In the illustrated embodiment, the circumference of the anvilroll outer surface 220 (e.g., including the bonding and cutting segments230, 236) is suitably sized to correspond generally to the length (e.g.,along the longitudinal axis 48) of each pair of the training pants 102of the product assemblage 113. For example, the length of the trainingpants 102 of the illustrated embodiment and the circumference of theanvil roll 210 can each be about 20 inches (about 50.8 mm). In such anarrangement, one revolution of the anvil roll 210 is intended tocorrespond to a single pair of training pants 102 passing through thenip 219 in the machine direction 108. However, the diameter and outercircumference of the anvil roll 210 may be sized for more than onerevolution per pair of training pants 102, or it may be sized for lessthan one revolution per pair of training pants 102 (e.g., one revolutionmay correspond to two or more pair of training pants passing through thenip).

[0107] In operation, the assemblage 113 of training pants 102 istransported in the machine direction 108 to the mechanical bonding andcutting apparatus 180. As the leading edge (e.g., the waist end edge 72)of a pair of training pants 102 of the assemblage 113 passes theapparatus 180, the side panel strip 118 corresponding to the back sidepanel 134 of the completed pants enters the nip 219 between the anvilroll 210 and bonding roll 216. The side panel strip 118 (with thefastening component 170 thereon) enters the nip 219 with the anvil roll210 in a rotational orientation corresponding to the bonding mode of theapparatus 180 in which the bonding segment 230 of the outer surface 220of the anvil roll (and more particularly the mid-portion of the bondingsegment 230 at which the anvil roll outer surface shown in FIG. 7 isbisected) defines the nip 219 together with the bonding roll 216. Atleast part of the cutting segment 236, and more suitably the entirecutting segment, is external of the nip 219. As the side panel strip 118passes through the nip 219 in the bonding mode of the apparatus 180, thebonding segment 230 and bonding roll 216 facilitate mechanical bondingof the fastening component 170 to the side panel strip.

[0108] Upon further transport of the assemblage 113 in the machinedirection 108 and upon further rotation of the anvil roll 210, thecutting segment 236 of the anvil roll outer surface 220 is rotated intoa position corresponding to the cutting mode of the apparatus 180 inwhich the cutting segment, and more particularly the first portion 240of the blade 238 defines the nip 219 together with the bonding roll 216and the bonding segment 230 is external of the nip. As the trailing edgeof the side panel strip 118 corresponding to the back side panel entersthe nip 219, the blade 238 cuts a portion of the side panel strip toform the leg end edge 70 of the back side panel 124. The anvil roll 210continues to rotate the rest of the cutting segment 236 through the nip219 so that upon further transport of the assemblage 113 in the machinedirection 108, a portion of the leading edge of the side panel strip 118corresponding to the front side panel 32 is cut by the second portion244 to form the leg end edge 70 of the front side panel. Cut material isremoved from the side panel strip 118 by allowing it to simply fall awayfrom the strip 118 or by using a conventional trim removal techniquesuch as vacuum and/or other suitable techniques.

[0109] The anvil roll 210 further rotates to a position and orientationin which the bonding segment 230 again defines the nip 219 together withthe bonding roll 216 as the remainder of the side panel strip 118corresponding to the front side panel 34 (along with the fasteningcomponent 160 thereon) passes through the nip 219. The fasteningcomponent 160 and side panel strip 118 are thus mechanically bondedtogether. The leading edge of the next pair of training pants 102 of theproduct assemblage then passes into the nip 219 as the anvil roll 210completes an entire revolution, with the bonding segment 230 stilldefining the nip.

[0110] While the mechanical bonding and cutting apparatus 180 is shownin the drawings and described herein as comprising two separate anvilrolls 210 spaced transversly from each other according to the spacingbetween the side panel strips 118, it is contemplated that a singleanvil roll (not shown) may extend in the cross-machine direction acrossall or part of the width of the assemblage 113. For example, the singleanvil roll may have a length equal to the width of the assemblage 113 atthe side panel strips 118. The anvil roll may have respective bondingand cutting segments toward the opposite ends thereof to correspond tothe positions of the side panel strips 118 as the assemblage 113 passesthe apparatus. The bonding rolls 216 are still transversely spaced fromeach other and are in opposed relationship with the single anvil roll atthe locations of the bonding and cutting segments of the anvil roll todefine the nips 219.

[0111] It is also contemplated that a single bonding roll (not shown)may extend transversely in opposed relationship with the single anvilroll along the length of the anvil roll to define a nip that extendsalong substantially the length of the anvil roll. It is furthercontemplated that the anvil roll may have cutting and bonding segmentsthereon for bonding and/or cutting portions of the assemblage 113intermediate the side panel strips 118, such as those portions of theassemblage which later define the waist end edges 72 of the pants 20.

[0112] At least one cutting segment may even extend across the fullwidth of the single anvil roll to cut the assemblage 113 into discrete,partially assembled pants 102. In such an embodiment, the bonding andcutting apparatus 180 may eliminate the need for the cutter 186 shown inFIG. 4 and described later herein.

[0113]FIG. 10 illustrates an alternative embodiment of the apparatus 180in which the anvil roll outer surface 320 comprises a bonding segment330 having a length shorter than the bonding segment 230 of the anvilroll outer surface 220 of FIG. 7. The shorter bonding segment 330 isintended to mechanically bond the fastening component 170 to the sidepanel strip 118 corresponding to the back side panel 134 as each pair oftraining pants 102 passes through the nip 219. The front side panel 34itself may function as a fastening component so that no mechanicalbonding is necessary on the side panel strip 118 corresponding to thefront side panel.

[0114]FIG. 11 illustrates another alternative embodiment of theapparatus 180 in which the anvil roll outer surface 420 comprises a pairof bonding segments 430 a, 430 b and a pair of cutting segments 436 a,436 b. The cutting segments 436 a, 436 b are circumferentially spacedfrom each other and are configured for cutting away portions of therespective side panel strips 118, e.g., to provide the angled and/orcurved leg end edges 70 of the front and/or back side panels 34, 134 ofthe pants 102. The cutting segments 436 a, 436 b comprise blades 438 a,438 b extending transversely and circumferentially of the outer surface420 of the anvil roll to define first and second cutting patterns whichare substantially similar to those defined by the cutting segment 236 ofthe anvil roll outer surface 220 of FIG. 7.

[0115] One of the bonding segments 430 a is substantially the same asthe bonding segment 230 of the anvil roll outer surface 220 of FIG. 7.The other bonding segment 430 b extends circumferentially of the anvilroll outer surface 420 intermediate the blades 438 a, 438 b of thecutting segments 436 a, 436 b. In the illustrated embodiment, endportions of the bonding segment 430 b circumferentially overlap thecutting segments 436 a, 436 b, i.e., the projections (not shown butsubstantially the same as the projections 222 of FIG. 7) of the bondingsegment at these end portions are generally transversely adjacent theblades 438 a, 438 b of the cutting segments. However, it is understoodthat the ends of the bonding segment 430 b may not circumferentiallyoverlap the cutting segments 436 a, 436 b, as long as the ends of thebonding segment 430 a, 430 b are positioned generally circumferentiallyadjacent to the ends of the cutting segments.

[0116] Operation of the apparatus of the alternative embodiment of FIG.11 is similar to that described previously for the embodiment of FIG. 7with the exception that as the first cutting segment 436 a exits the nip219 upon rotation of the anvil roll, the bonding segment 430 bintermediate the cutting segments 436 a, 436 b is disposed within thenip until the anvil roll rotates further to a position in which thesecond cutting segment 436 b defines the nip together with the bondingroll 216. As a result, there is less of a transition (e.g., a lesserchange in surface height between the blade 438 a and the outer ends ofthe projections 222 of the bonding segment 430 b of the anvil roll outersurface 420) as the anvil rotates between the first cutting segment 436a and the second cutting segment 436 b. For example, if the bondingsegment 430 b is omitted, there would be a greater height transition(e.g., from the blade height to the reference surface, or referencediameter) following rotation of the first cutting segment 436 a throughthe nip. Where the anvil roll 210 and bonding roll 216 remain in contactwith each other throughout rotation of the anvil roll, a lesser changein surface height between the cutting segments 436 a, 436 b, reduces theimpact of the blade 438 b with the bonding roll as the blade forming thesecond cutting segment 436 b enters the nip 219.

[0117] While the bonding segments 230, 330, 430 and cutting segments236, 436 a, 436 b of the illustrated embodiments of FIGS. 6-11 aredisposed on the anvil roll outer surface 220, 320, 420, it is understoodthat the bonding segments and cutting segments may instead be disposedon the bonding roll 216. It is also contemplated that one or morebonding segments may be disposed on the anvil roll 210 while one or morecutting segments are disposed on the bonding roll 216, or vice versa,without departing from the scope of this invention.

[0118] Also, the apparatus and method illustrated herein is a generallysequential mechanical bonding and cutting operation in which thetraining pants 102 are first mechanically bonded, then subjected to acutting operation, and, in certain embodiments, are subjected to furthermechanical bonding. However, it is understood that the mechanicalbonding and cutting may be conducted in any sequential order and remainwithin the scope of this invention. It is also contemplated that theapparatus 180 may be configured such that mechanical bonding and cuttingof the training pants 102 occur simultaneously. For example a bondingsegment and cutting segment may at least partially concurrently definethe nip 219 upon rotation of the anvil roll 210, such as where thebonding segment and cutting segment are disposed at substantially thesame circumferential location of the anvil roll outer surface.

[0119] After passing the mechanical cutting and bonding apparatus 180,the assemblage 113 is passed through the cutter 186 which selectivelycuts the assemblage into discrete, partially assembled training pants102. Such cutters 186 are generally known to those skilled in the artand can include, for example, the combination of a cutting roll 187 andan anvil roll 188 through which the web travels.

[0120] The anvil roll 188 can include a hardened steel rotating rollwhile the cutting roll 187 can include one or more flexible hardenedsteel blades clamped onto another rotating roll. The pinching forcebetween the blade on the cutting roll 187 and the anvil roll 188 createsthe cut. The cutting roll 187 can have one or more blades depending uponthe desired distance between the cuts. The cutter 186 can further beconfigured to provide a spacing between the individual cut pieces afterthey are cut. Such a spacing can be provided by transferring the cutpieces away from the cutter at a higher speed than the speed at whichthe web is provided to the cutter.

[0121] As various changes could be made in the above constructions andmethods, without departing from the scope of the invention, it isintended that all matter contained in the above description and shown inthe accompanying drawings shall be interpreted as illustrative and notin a limiting sense.

[0122] When introducing elements of the invention or the preferredembodiment(s) thereof, the articles “a”, “an”, “the” and “said” areintended to mean that there are one or more of the elements. The terms“comprising”, “including” and “having” are intended to be inclusive andmean that there may be additional elements other than the listedelement.

What is claimed is:
 1. A method of mechanically bonding and cutting an article during assembly thereof, said method comprising: transporting the article in a machine direction during assembly thereof such that at least part of the article passes through a nip as the article is transported in the machine direction; mechanically bonding a portion of the article as said article passes through the nip; and cutting a portion of the article separate from said bonded portion as said article passes through the nip.
 2. A method as set forth in claim 1 wherein the mechanical bonding step is performed prior to the cutting step.
 3. A method as set forth in claim 2 wherein the bonded portion of the article is a first bonded portion thereof, said method further comprising mechanically bonding a portion of the article separate from the first bonded portion and the cut portion of the article to define a second bonded portion thereof, said cutting step being performed prior to mechanically bonding said second bonded portion of the article.
 4. A method as set forth in claim 1 wherein the nip is defined in part by a rotatable roll having a circumferential outer surface comprising a bonding segment configured for mechanically bonding the article and a cutting segment configured for cutting the article, the mechanical bonding step comprising rotating the roll such that the nip is in part defined by the bonding segment of the outer surface of the roll, the cutting step comprising rotating the roll such that the nip is in part defined by the cutting segment of the outer surface of the roll.
 5. A method as set forth in claim 4 wherein the article has a length in the machine direction, said method further comprising rotating the roll through one complete revolution as the full length of the article passes through the nip.
 6. A method as set forth in claim 1 wherein the mechanical bonding comprises ultrasonic bonding.
 7. A method as set forth in claim 1 wherein the article has a longitudinal axis, a transverse axis, and first and second longitudinal ends generally defining a length of the article, said transporting step comprising transporting the article in the machine direction such that the article passes, first longitudinal end first, through said nip, the cutting step comprising cutting a portion of the article intermediate the longitudinal ends thereof to remove said cut portion from the article to thereby at least in part define leg openings of the article.
 8. A method as set forth in claim 7 wherein the mechanical bonding step is performed prior to the cutting step.
 9. A method as set forth in claim 1 wherein the article comprises disposable pants having a side panel extending transverse to the machine direction in which the pants are transported, said transporting step comprising transporting the pants in the machine direction such that the side panel passes through the nip as the pants are transported in the machine direction, the mechanical bonding step comprising mechanically bonding a portion of the side panel as the side panel passes through the nip, the cutting step comprising cutting a portion of the side panel separate from the bonded portion as the side panel passes through the nip.
 10. A method as set forth in claim 9 wherein the pants comprises first and second side panels spaced from each other in the machine direction and extending generally transverse to the machine direction in which the pants are transported, the transporting step comprising sequentially passing the side panels through the nip as the pants are transported in the machine direction, the mechanical bonding step comprising mechanically bonding a portion of one of the first and second side panels as the side panels pass through the nip, the cutting step comprising cutting a portion of one of the first and second side panels separate from said bonded portion as the side panels pass through the nip.
 11. A method as set forth in claim 10 further comprising mechanically bonding a portion of another one of said first and second side panels.
 12. A method as set forth in claim 11 wherein the cutting step is performed after mechanically bonding a portion of one of said first and second side panels and prior to mechanically bonding a portion of another one of said first and second side panels.
 13. A method as set forth in claim 10 further comprising cutting a portion of another one of said first and second side panels as the side panels pass through the nip.
 14. A method as set forth in claim 1 further comprising positioning a fastening component on the article upstream of the nip, said transporting step comprising passing said article and fastening component together through the nip as the article is transported in the machine direction, the bonding step comprising mechanically bonding the fastening component to the article as said article and fastening component pass through the nip.
 15. A method as set forth in claim 1 wherein the cutting step comprises cutting said portion of the article in a direction at least in part transverse to the machine direction in which the article is transported.
 16. Apparatus for mechanically bonding and cutting an article upon movement of the article in a machine direction, said apparatus comprising: a first member and a second member arranged relative to the first member to define a nip therebetween for receiving the article therethrough upon movement of the article in the machine direction; a bonding segment on one of the first and second members, said bonding segment being configured for mechanically bonding the article; and a cutting segment on one of the first and second members, said cutting segment being configured for cutting the article; the apparatus being operable in a bonding mode in which the nip is defined in part by the bonding segment and the cutting segment is disposed external of the nip such that a portion of the article is mechanically bonded as the article passes through the nip, and a cutting mode in which the nip is defined in part by the cutting segment and the bonding segment is disposed external of the nip whereby a portion of the article other than the bonded portion thereof is cut as the article passes through the nip.
 17. Apparatus as set forth in claim 16 wherein the bonding segment and the cutting segment are disposed on the first member of said apparatus, the first member being positionable between a bonding position corresponding to the bonding mode of the apparatus wherein the bonding segment in part defines the nip and the cutting segment is disposed external of the nip, and a cutting position corresponding to the cutting mode of the apparatus wherein the cutting segment in part defines the nip and the bonding segment is disposed external of the nip.
 18. Apparatus as set forth in claim 17 wherein the first member is a roll having a circumferential outer surface, said bonding segment extending circumferentially on said outer surface of the roll, said cutting segment extending circumferentially on said outer surface of the roll separate from the bonding segment, said roll being rotatably driven between the bonding position in which the bonding segment is rotatably positioned in opposed relationship with the second member to define the nip therebetween and the cutting segment is external of the nip, and the cutting position in which the cutting segment is rotatably positioned in opposed relationship with the second member to define the nip therebetween and the bonding segment is external of the nip.
 19. Apparatus as set forth in claim 18 wherein the second member is a roll disposed in generally parallel relationship with the roll defining the first member.
 20. Apparatus as set forth in claim 18 wherein the roll defining the first member is an anvil roll and the second member is an ultrasonic horn whereby in the bonding mode the article is ultrasonically bonded as it passes through the nip.
 21. Apparatus as set forth in claim 18 wherein the bonding segment is configured to mechanically bond a portion of the article within a bonding region thereof while the remainder of the bonding region is free of mechanical bonds.
 22. Apparatus as set forth in claim 21 wherein the bonding segment comprises a plurality of projections extending outward from the outer surface of the roll.
 23. Apparatus as set forth in claim 18 wherein the cutting segment comprises a blade projecting outward from the outer surface of the roll.
 24. Apparatus as set forth in claim 23 wherein the cutting blade extends at least in part transverse to the circumference of the roll.
 25. Apparatus as set forth in claim 23 wherein the cutting blade extends at least in part transverse to the machine direction in which the article passes through the nip.
 26. Apparatus as set forth in claim 16 wherein the bonding segment is a first bonding segment, the apparatus further comprising a second bonding segment on one of the first and second members separate from the first bonding segment.
 27. Apparatus as set forth in claim 26 wherein the apparatus is operable to position the first and second members in a first bonding position wherein the first bonding segment at least partially defines the nip and the second bonding segment is external of the nip and a second bonding position wherein the second bonding segment at least partially defines the nip and the first bonding segment is external of the nip.
 28. Apparatus as set forth in claim 16 wherein the cutting segment is a first cutting segment, the apparatus further comprising a second cutting segment on one of the first and second members separate from the first cutting segment, said second cutting segment being configured for cutting the article.
 29. Apparatus as set forth in claim 28 wherein the apparatus is operable to position the first and second members in a first position wherein the first cutting segment at least partially defines the nip and the second cutting segment is external of the nip and a second position wherein the second cutting segment at least partially defines the nip and the first cutting segment is external of the nip.
 30. Apparatus as set forth in claim 29 wherein the first member is a roll having a circumferential outer surface, said first bonding segment extending circumferentially on said outer surface of the roll, said first cutting segment extending circumferentially on said outer surface of the roll separate from the bonding segment, said second cutting segment extending circumferentially on said outer surface of the roll separate from the bonding segment and separate from the first cutting segment.
 31. Apparatus as set forth in claim 30 wherein the bonding segment is a first bonding segment, the apparatus further comprising a second bonding segment separate from the first bonding segment and extending circumferentially on the outer surface of the roll.
 32. Apparatus for mechanically bonding and cutting an article upon movement of the article in a machine direction, said apparatus comprising: a first member and a second member arranged relative to the first member to define a nip therebetween for receiving the article therethrough upon movement of the article in the machine direction; a bonding segment on one of the first and second members, said bonding segment being configured for mechanically bonding the article; and a cutting segment on one of the first and second members, said cutting segment being separate from the bonding segment and configured for cutting the article; the apparatus being operable to position the first and second members relative to each other at the nip such that at least one of the bonding segment and the cutting segment at least partially defines the nip as the article passes therethrough.
 33. Apparatus as set forth in claim 32 wherein the bonding segment is configured for bonding a portion of the article as the article passes through the nip and the cutting segment is configured for cutting a portion of the article separate from the bonded portion thereof as the article passes through the nip.
 34. Apparatus as set forth in claim 33 wherein the bonding segment and the cutting segment are disposed on the first member of said apparatus, the first member being positionable between a bonding position wherein the bonding segment in part defines the nip and the cutting segment is disposed external of the nip, and a cutting position corresponding wherein the cutting segment in part defines the nip and the bonding segment is disposed external of the nip.
 35. Apparatus as set forth in claim 33 wherein the first member is a roll having a circumferential outer surface, said bonding segment extending circumferentially on said outer surface of the roll, said cutting segment extending circumferentially on said outer surface of the roll separate from the bonding segment, said roll being rotatably driven between the bonding position and the cutting position.
 36. Apparatus as set forth in claim 35 wherein the second member is a roll disposed in generally parallel relationship with the roll defining the first member.
 37. Apparatus as set forth in claim 35 wherein the roll defining the first member is an anvil roll and the second member is an ultrasonic horn whereby in the bonding position the article is ultrasonically bonded as it passes through the nip.
 38. Apparatus as set forth in claim 32 wherein the bonding segment is a first bonding segment, the apparatus further comprising a second bonding segment on one of the first and second members separate from the first bonding segment, said second bonding segment being configured for mechanically bonding the article.
 39. Apparatus as set forth in claim 38 wherein the apparatus is operable to position the first and second members in a first bonding position wherein the first bonding segment at least partially defines the nip and the second bonding segment is external of the nip and a second bonding position wherein the second bonding segment at least partially defines the nip and the first bonding segment is external of the nip.
 40. Apparatus as set forth in claim 38 wherein the cutting segment is a first cutting segment, the apparatus further comprising a second cutting segment on one of the first and second members separate from the first cutting segment, said second cutting segment being configured for cutting the article.
 41. Apparatus as set forth in claim 40 wherein the apparatus is operable to position the first and second members in a first position wherein the first cutting segment at least partially defines the nip and the second cutting segment is external of the nip and a second position wherein the second cutting segment at least partially defines the nip and the first cutting segment is external of the nip.
 42. Apparatus as set forth in claim 41 wherein the first member is a roll having a circumferential outer surface, said bonding segment extending circumferentially on said outer surface of the roll, said first cutting segment extending circumferentially on said outer surface of the roll separate from the bonding segment, said second cutting segment extending circumferentially on said outer surface of the roll separate from the bonding segment and separate from the first cutting segment.
 43. Apparatus as set forth in claim 42 wherein the bonding segment is a first bonding segment, the apparatus further comprising a second bonding segment separate from the first bonding segment and extending circumferentially on the outer surface of the roll. 